Method of installing a mastic footprint for structures

ABSTRACT

The method of installing the mastic footprint may be used as a repair or in connection with a new installation of the structure. The method produces a mastic footprint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic footprint that is thermally resistant. In repairs, the mastic footprint of the method provides longevity of use of at least one year and up to 5 years prior to any repair or replacement. In new installations, the mastic footprint provides longevity of use of at least 1 year and up to 15 years prior to any repair or replacement. Finally, the method of installing a mastic footprint does not affect the structural integrity of the adjacent or surrounding surface material, where the adjacent or surrounding surface material does not require repair or replacement sooner than if the method had not been deployed.

This application claims the benefit of U.S. Provisional Application No. 63/309,115 entitled “METHOD OF INSTALLING A MASTIC FOOTPRINT FOR STRUCTURES” filed Feb. 11, 2022, which is incorporated by reference in its entirety.

BACKGROUND

Structures, such as manholes, spill buckets, and fuel islands, where the installed structure contacts concrete are susceptible to erosion (concrete spalling and subbase failures) at this area of contact (i.e. the seam). Erosion occurs when water, fuel, or salt contacts this seam between the concrete and structure, where the water infiltrates the seam to erode the concrete and the subbase (e.g. gravel or dirt) underneath the concrete. This erosion weakens the structural integrity of the concrete leading to crumbling or fracturing of the concrete. Additionally this water infiltration of the seam may cause structural integrity damage to the structure itself, such as rusting, settling, erosion, and other damage.

Erosion is hastened by temperature changes (freezing and thawing) of the ground that cause movement and breakage of the concrete, in particular, at the joints of concrete slabs, or other weak areas, such as the seam between the concrete and a structure. An example of this damage is shown in FIG. 6 where the joints of concrete slabs 10 and seams between the concrete and structure are 12 (seams are also bolded).

The damage produced from this erosion effects the safety of the structures, increasing the risk that the structure will cease to be usable for its intended purpose and decreasing the amount of time before structure replacement and concrete repair or replacement. Further, this damage produces an uneven surface affecting the ability to easily travel over and around the structure on foot or in a vehicle.

Conventional methods for repairing the seam and concrete or asphalt that has erosion around a structure include application of a cold patch to the eroded and/or damaged concrete. Cold patching damaged concrete does provide a level surface. However, the cold patch is not waterproof, so immediately after patching water begins the erosion process both at the seam of the structure and any other location where the cold patch meets the concrete or asphalt. Further, the longevity of the cold patch is approximately six months to one year in length, where after this time erosion requires replacement of the cold patch.

Another conventional method for repairing the seam and concrete is complete replacement of the concrete slab having the eroded concrete with a new concrete slab. However, new concrete will immediately after installation begin the erosion process at the seam of the structure. Additionally, complete replacement of the concrete is time consuming (concrete requires approximate cure times as follows: 1 day to receive foot traffic, 3 days to receive light traffic, 7 days to receive heavy traffic (i.e. semis), and 28 days to reach full strength) and requires more material than repairing or patching the concrete.

A conventional method for installation of sanitary manholes to reduce erosion and maintain integrity of the structure includes installation with a rubber boot surrounding the sanitary manhole. The rubber boot is designed to provide a watertight seal around the sanitary manhole to protect against water from entering into the manhole. However, the conventional rubber boot does not move with the manhole (i.e. it is not adhered to the manhole) such that the rubber boot does not provide a water tight seal leading to erosion and structural damage.

Another conventional method for new installation of structures includes caulking the seam of the structure and surface material. This caulk is designed to provide a watertight seal around between the structure and surface material. However, the caulk is not temperature resistant, nor salt resistant, and as the concrete fluctuates the caulk is pulled away from the structure and/or concrete producing holes to open the structure and concrete to water, salt, and fuel hastening erosion and structure damage.

It is therefore desirable to have a method for repairing the seam between a structure and the adjacent concrete that provides longevity of use (i.e. more than one year before another repair must be made). It is further desirable to have a method of installation of a structure having a seam between the structure and concrete that provides longevity of use. It is further desirable to have a method of repairing or installing a seam between the structure and concrete that is resistant to damage (i.e. cracking, creation of a gap) during temperature changes. It is further desirable to have method of repairing or installing a seam between the structure and concrete that takes less than one day to cure for receiving traffic. Finally, it is desirable to have a method of repairing or installing a seam between the structure and concrete that eliminates additional structural components (i.e. eliminates the need for a rubber boot around a sanitary manhole).

SUMMARY

In aspects, a mastic footprint around a structure, the mastic footprint includes parameters that provide water, fuel, salt and thermal resistance, where the parameters comprise a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees; wherein the mastic footprint is produced by preparing the surface material to the parameters; preparing the structure; preparing a footprint; applying hot mastic to the footprint to install the mastic footprint, the applying includes mixing the mastic with a bulking stone, where the bulking stone is from 25% to 80% of the mastic footprint.

In aspects a method of installing a mastic footprint that is water, fuel, salt, and temperature resistant at a structure, the method including cutting the surface material based on predetermined parameters, the predetermined parameters including a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees; preparing the structure; preparing a footprint; applying hot mastic to the footprint to install the mastic footprint, the applying includes mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 25% to 80% of the mastic footprint.

In aspects, the method according to paragraph [0010], wherein the surface material is concrete.

In aspects, the method according to paragraph [0010], wherein the surface material is asphalt.

In aspects, the method of paragraph [0010], wherein preparing the footprint comprises applying denatured alcohol to the adjacent surface material and structure.

In aspects, the method of paragraph [0011], wherein the minimum depth is equal to the depth of the surface material, and wherein the bulking stone is from 40% to 80% of the mastic footprint.

In aspects, the method of paragraph [0013] wherein preparing the footprint further comprises removing dirt, rust, and debris from the structure for proper adherence of the mastic footprint to the structure.

In aspects, the method of paragraph [0015], wherein the structure is a fuel island.

In aspects, the method of paragraph [0015], wherein the structure is a spill bucket.

In aspects, the method of paragraph [0015], wherein the structure is a manhole.

In aspects, the method of paragraph [0010], wherein the minimum depth is from at least 2.54 centimeters to less than the depth of the surface material, and wherein the bulking stone is from 25% to 50% of the mastic footprint.

In aspects, a method of installing a mastic footprint at a structure, the method includes forming the surface material based on predetermined parameters, the predetermined parameters includes a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees;

-   -   preparing the structure; preparing a footprint; applying hot         mastic to the footprint to install the mastic footprint, the         applying includes mixing a mastic base that is hot with a         bulking stone, where the bulking stone is from 25% to 80% of the         mastic footprint.

In aspects, the method of paragraph [0020], wherein the surface material is concrete.

In aspects, the method of paragraph [0020], wherein the surface material is asphalt.

In aspects, the method of paragraph [0020], wherein preparing the footprint includes applying denatured alcohol to the adjacent surface material and structure.

In aspects, the method of [0021], wherein the minimum depth is equal to the depth of the surface material, and wherein the bulking stone is from 40% to 80% of the mastic footprint.

In aspects, the method of paragraph [0023], wherein preparing the footprint further includes removing dirt, rust, and debris from the structure for proper adherence of the mastic footprint to the structure.

In aspects, the method of paragraph [0025], wherein the structure is a fuel island.

In aspects, the method paragraph [0025], wherein the structure is a spill bucket.

In aspect, the method of paragraph [0025], wherein the structure is a manhole.

In aspect, the method of paragraph [0020], wherein the minimum depth is from at least 2.54 centimeters to less than the depth of the surface material, and wherein the bulking stone is from 25% to 50% of the mastic footprint.

FIGURES

FIG. 1 is a method of installing a mastic footprint for a structure.

FIG. 2 represents a mastic footprint having a portion that does not receive vehicle traffic and a mastic footprint that has more than one structure.

FIG. 3 represents a mastic footprint that receives vehicle traffic and a mastic footprint that has one structure.

FIG. 3 a represents a vertical cross section of the mastic footprint of FIG. 3 .

FIG. 4 represents a cross section of a mastic footprint that receives vehicle traffic and a mastic footprint that has one structure.

FIG. 4 a represents a vertical cross section of the mastic footprint of FIG. 4 .

FIG. 5 represents a vertical, longitudinal cross section of the mastic footprint of FIG. 2 .

FIG. 6 represents an example of erosion that occurs with a surface material having conventionally installed structures.

DETAILED DESCRIPTION

As used herein, the following terms have the accompanying defined meaning:

“Mastic” means a material for hot application that is a polymer binder with factory blended fillers, fine aggregate, and fibers, including reinforcing (bulking) stone (e.g. granite aggregate) having the capability of (1) withstanding motor vehicle (including semis) weight without deformation of the mastic, (2) adhering to surface material and structure, (3) preventing melting or deteriorating of plastic of the structure, (4) resisting water, fuel, and salt (i.e. the mastic resists infiltration by water, fuel, salt, and mixtures thereof), (5) resisting thermal fluctuations (i.e. the mastic remain flexible under temperature changes to maintain adhesion to the surface material and structure).

“Bulking stone” means a fine aggregate that provides volume when added to the mastic, where the fine aggregate is from 0.3175 to 1.905 centimeters (0.125 to 0.75 inches). Preferably the fine aggregate is from 0.3175 to 0.635 centimeters (0.125 to 0.25 inches). The bulking stone may be of any material that is non-reactive with the mastic, such as, granite, quartz, limestone, pea gravel, and the like.

“Structure” means a fabricated installation that includes steel and may include concrete, where the steel and/or concrete is in contact with the surface material concrete or asphalt. For example, structures include manholes, spill buckets, and fuel islands, where the fuel island includes canopy column(s), fuel pump island, and bumper posts.

“Seam” means the area of contact between the structure and surface material or mastic.

“Surface material” means concrete or asphalt.

“Footprint” means the area of mastic that is installed to repair and replace the seam. When a mastic footprint is installed as part of new construction the footprint replaces the seam.

A method of installing a mastic footprint at a structure is described. The method of installing the mastic footprint may be used as a repair (i.e. erosion of the seam of the concrete and structure has occurred) or in connection with a new installation of the structure. The method produces a mastic footprint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic footprint that is thermally resistant (i.e. the mastic remains flexible at varying temperatures such that adherence of the mastic to the adjacent surface material and structure is maintained). In repairs, the mastic footprint of the method provides longevity of use of at least one year and up to 5 years prior to any repair or replacement. In new installations, the mastic footprint provides longevity of use of at least 1 year and up to 15 years when in regions having a freeze and thaw cycle similar to that of the Midwest region. prior to any repair or replacement. Finally, the method of installing a mastic footprint does not affect the structural integrity of the adjacent or surrounding surface material, where the adjacent or surrounding surface material does not require repair or replacement sooner than if the method had not been deployed.

FIG. 1 represents a method 100 of installing a mastic footprint at a structure is described. In 102, the surface material is prepared. When installing a mastic footprint as a repair, the surface material is cut with a saw or router configured for cutting the surface material type. When installing a mastic footprint as part of a new installation, the surface material is prepared (e.g. concrete is poured) based on a predetermined mastic footprint parameters. The parameters of the mastic footprint include placement of the footprint to provide that the footprint is water, salt, fuel (including mixtures of water, salt, and fuel thereof) and thermal resistance, which provide longevity of use as erosion is significantly delayed or prevented by such resistances. The parameters of the mastic footprint also require the mastic footprint to not adversely affect the adjacent and surrounding surface material.

The parameters of the mastic footprint that provide water and thermal resistance are minimum distance between the structure and any edge of the mastic footprint (i.e. minimum distance) and depth of the mastic footprint. The minimum distance is at least 15.24 centimeters (6 inches), which includes 15.24 centimeters. The minimum distance ensures that there is sufficient distance between the structure and the adjacent concrete to install the mastic footprint according to the method 100 for adherence of the mastic footprint to the structure and adjacent surface material. For example, the minimum distance 204 between the structure 202 and the adjacent surface material of FIGS. 2, 3, and 4 is at least 15.24 centimeters (6 inches) for the mastic footprint 200.

The parameter of depth of the mastic footprint that provides water, fuel, salt, and thermal resistance is determined based on the concrete depth. The mastic footprint may be full depth of the concrete. The mastic footprint may be partial depth of the concrete. In instances where the mastic footprint is partial depth, the minimum depth of the mastic is at least 2.54 centimeters (1 inch) to provide the water, fuel, salt and thermal resistances. When the mastic footprint is used as a repair, partial depth repair is not done when the adjacent concrete shows signs of erosion or damage. Preferably, when the mastic footprint is installed as part of a new installation, the mastic footprint is full depth.

The parameter of the mastic footprint that does not adversely affect the adjacent or surrounding surface material is the shape of the mastic footprint. Taking the minimum distance into account, mastic footprints are shaped to minimize (reduce) the number of times the mastic footprint will cross existing surface material joints at approximately 90 degree angles. Crossing existing surface material joints at approximately 90 degrees may weaken the existing surface material causing damage in the installation process. Rather, than crossing an existing surface material joint at 90 degrees, the mastic footprint is designed to meet the existing surface material joint at an angle (i.e. an angle from 10 to 80 degrees and 100 to 170 degrees). Preferably, the angle is from 40 to 50 degrees.

The footprint design to meet a surface material joint at the angle reduces the amount of damage (breakage) to the surface material along the entirety of the line, thus increasing the ability to the mastic footprint to adhere to the adjacent surface material. Increasing the ability of the mastic footprint to adhere to the adjacent footprint provides that the adjacent surface material is not adversely affected and may increase the longevity of the adjacent concrete joint. For example, FIGS. 2, 3, and 4 include mastic footprints, where the diamond shape of the mastic footprint 200 minimize the mastic footprint from crossing the existing surface material joints 208 at 90 degrees, as opposed to another shape for the mastic footprint, such as a square or rectangle. Rather, for example, the mastic footprint 200 crosses existing surface material joints at an angle 206 from 40 to 50 degrees.

In 104, the structure is prepared. In new installations, the structure may be installed or verified to be in the correct location. In repair, preparing the structure includes examining the integrity of the structure to assess whether any repair or replacement of the structure is required.

In 106, a footprint is prepared for receiving the mastic. The footprint preparation includes ensuring the subbase is level with the bottom of the adjacent surface material, which may include removing debris, adding subbase material and/or smoothing the subbase. Preparation of the footprint may further include removal of any rust, dirt, or debris from the structure to produce the structure of bare surface, such as through sandblasting or grinding.

Preparation of the footprint further includes ensuring the footprint, adjacent concrete, and structure is dry, and the pores of the surface material and structure are clean to create binding elasticity between the mastic and the surface material and structure. Preparation of the footprint includes application of denatured alcohol, which may be followed by application of a primer (e.g. mastic primer, water-based elastomeric coating and sealant that is acrylic resin) to the adjacent surface material and structure to promote adherence of the mastic to the adjacent concrete and structure. Preparation of the footprint provides for maximum adherence of the mastic to the adjacent surface material, while using the least amount of mastic, thus increasing the efficiency of the installation process. An example of a level subbase is shown as 306 in FIG. 3 a , FIG. 4 a , and FIG. 5 .

In 108, the mastic is applied to the prepared footprint forming the mastic footprint. The mastic is applied in accordance with mastic manufacturer specifications. The application of the mastic includes applying the mastic to the footprint hot, while mixing the mastic base (i.e. mastic without bulking stone added) with bulking stone, where from 25%-80% of the mastic is bulking stone (i.e. bulking stone percentage). In full depth mastic footprints, the bulking stone percentage is from 40% to 80%, and in partial depth mastic footprints, the bulking stone percentage is from 25% to 50% to mastic. Preferably, the mastic is not placed in lifts exceeding 7.62 centimeters (3 inches) to speed with cooling and mixture of the bulking stone. Applying the mastic may include phased application. Cooling of the mastic to cure for receiving traffic takes the approximate time frames: 1 hour for receipt of foot traffic, 6 hours for the receipt of light and heavy vehicle traffic.

Application of the mastic may include placement of the mastic to provide a slight grade (i.e. from 0.5% to 2%) away from the structure. The grade provides that there will not be a low point by the structure to avoid or reduce pooling of water, salt, fuel, and mixtures thereof at or near the structure, which aides in longevity of the mastic footprint. 

1. A method of installing a mastic footprint that is water, fuel, salt, and temperature resistant at a structure, the method comprising: cutting the surface material based on predetermined parameters, the predetermined parameters comprising a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees; preparing the structure; preparing a footprint; applying hot mastic to the footprint to install the mastic footprint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 25% to 80% of the mastic footprint.
 2. The method of claim 1, wherein the surface material is concrete.
 3. The method of claim 1, wherein the surface material is asphalt.
 4. The method of claim 1, wherein preparing the footprint comprises applying denatured alcohol to the adjacent surface material and structure
 5. The method of claim 2, wherein the minimum depth is equal to the depth of the surface material, and wherein the bulking stone is from 40% to 80% of the mastic footprint.
 6. The method of claim 4, wherein preparing the footprint further comprises removing dirt, rust, and debris from the structure for proper adherence of the mastic footprint to the structure.
 7. The method of claim 6, wherein the structure is a fuel island.
 8. The method of claim 6, wherein the structure is a spill bucket.
 9. The method of claim 6, wherein the structure is a manhole.
 10. The method of claim 1, wherein the minimum depth is from at least 2.54 centimeters to less than the depth of the surface material, and wherein the bulking stone is from 25% to 50% of the mastic footprint.
 11. A method of installing a mastic footprint at a structure, the method comprising: forming the surface material based on predetermined parameters, the predetermined parameters comprising a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees; preparing the structure; preparing a footprint; applying hot mastic to the footprint to install the mastic footprint, the applying comprising mixing a mastic base that is hot with a bulking stone, where the bulking stone is from 25% to 80% of the mastic footprint.
 12. The method of claim 11, wherein the surface material is concrete.
 13. The method of claim 11, wherein the surface material is asphalt.
 14. The method of claim 11, wherein preparing the footprint comprises applying denatured alcohol to the adjacent surface material and structure
 15. The method of claim 12, wherein the minimum depth is equal to the depth of the surface material, and wherein the bulking stone is from 40% to 80% of the mastic footprint.
 16. The method of claim 14, wherein preparing the footprint further comprises removing dirt, rust, and debris from the structure for proper adherence of the mastic footprint to the structure.
 17. The method of claim 16, wherein the structure is a fuel island.
 18. The method of claim 16, wherein the structure is a spill bucket.
 19. The method of claim 16, wherein the structure is a manhole.
 20. The method of claim 11, wherein the minimum depth is from at least 2.54 centimeters to less than the depth of the surface material, and wherein the bulking stone is from 25% to 50% of the mastic footprint.
 21. A mastic footprint around a structure, the mastic footprint comprising: parameters that provide water, fuel, salt and thermal resistance, where the parameters comprise a minimum distance of at least 15.24 centimeters, a minimum depth of at least 2.54 centimeters, a shape for the mastic footprint that does not adversely affect adjacent surface material, where the shape minimizes the mastic footprint from crossing an existing surface material joint at an angle of 80 to 100 degrees; wherein the mastic footprint is produced by preparing the surface material to the parameters; preparing the structure; preparing a footprint; applying hot mastic to the footprint to install the mastic footprint, the applying comprising mixing the mastic with a bulking stone, where the bulking stone is from 25% to 80% of the mastic footprint. 